Intake gas sensor with vortex for internal combustion engine

Abstract

A gas sensor includes a sensor housing and a sensing element located within the sensor housing. The sensing element defines an axis. The sensing element has a distal end extending from the sensor housing. The gas sensor further includes a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection element includes a tube having a conical portion, and a gas inlet located on the tube, the gas inlet spaced from the axis. The gas inlet is shaped to direct gas into the tube to induce a vortex gas flow within the conical portion of the tube.

What is claimed is: 
     
       1. A gas sensor comprising:
 a sensor housing; 
 a sensing element located within the sensor housing, the sensing element defining a first axis and having a distal end extending from the sensor housing; and 
 a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element, the sensor protection element including:
 an outer tube having a first conical portion, the first conical portion having an inner surface, the outer tube further having a gas inlet, the gas inlet spaced from the first axis, the gas inlet shaped to direct gas into the outer tube to induce a vortex gas flow within the first conical portion of the outer tube, wherein the gas inlet is shaped as one of an outwardly facing scoop structure having an inner concave surface or an inwardly facing scoop structure having an outer concave surface, wherein the gas inlet is configured to direct gas into the first conical portion generally tangentially to the inner surface of the first conical portion, and wherein the outer tube further includes a first gas outlet; and 
 an inner tube disposed within the outer tube, wherein the inner tube has a second conical portion that tapers in diameter along the first axis, such that the second conical portion has a diameter that decreases along a direction moving away from the sensing element along the first axis. 
 
 
     
     
       2. The gas sensor of  claim 1 , wherein the gas inlet is on the first conical portion. 
     
     
       3. The gas sensor of  claim 1 , wherein the sensor protection element further includes a waste outlet located on the first conical portion. 
     
     
       4. The gas sensor of  claim 3 , wherein the first axis extends through the waste outlet. 
     
     
       5. The gas sensor of  claim 1 , wherein the outer tube further includes a cylindrical portion. 
     
     
       6. The gas sensor of  claim 5 , wherein the gas inlet is on the cylindrical portion. 
     
     
       7. The gas sensor of  claim 5 , wherein the first gas outlet is located on the cylindrical portion. 
     
     
       8. The gas sensor of  claim 1 , wherein the distal end of the sensing element is located within the inner tube. 
     
     
       9. The gas sensor of  claim 1 , wherein the gas inlet is a first gas inlet, and the gas sensor protection element further includes a second gas inlet located on the inner tube at a distal end of the second conical portion. 
     
     
       10. The gas sensor of  claim 9 , wherein the first axis extends through the second gas inlet. 
     
     
       11. The gas sensor of  claim 1 , wherein the inner tube includes a second gas outlet spaced from the first axis, wherein a second axis extends through at least a portion of both the first gas outlet and the second gas outlet, the second axis extending perpendicular to the first axis. 
     
     
       12. A gas sensor comprising:
 a sensor housing; 
 a sensing element located within the sensor housing, the sensing element defining a first axis and having a distal end extending from the sensor housing; and 
 a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element, the sensor protection element including:
 an outer tube having a conical portion; 
 a first gas inlet located on the outer tube, the first gas inlet spaced from the first axis; 
 a waste outlet located on the conical portion, the first axis extending through the waste outlet; 
 an inner tube disposed within the outer tube, the sensing element located within the inner tube; 
 a second gas inlet located on the inner tube, the first axis extending through the second gas inlet; 
 a first gas outlet located on the inner tube, the first gas outlet spaced from the first axis; and 
 a second gas outlet located on the outer tube, the second gas outlet spaced from the first axis, such that a portion of the gas entering the first gas inlet is configured to pass out the waste outlet without passing through the second gas inlet, 
 wherein a second axis extends perpendicular to the first axis, the second axis extending through the second gas outlet, and wherein the first gas outlet includes an indented channel defined by a radially inwardly extending indentation of the inner tube, wherein the first gas outlet includes openings on opposite ends of the indented channel, the openings spaced from the second axis and also spaced circumferentially from one another along the inner tube. 
 
 
     
     
       13. The gas sensor of  claim 12 , wherein the second axis extends through at least a portion of both the first gas outlet and second gas outlet. 
     
     
       14. The gas sensor of  claim 12 , wherein the first gas inlet is shaped to direct gas into the outer tube to induce a vortex gas flow between the outer tube and the inner tube. 
     
     
       15. The gas sensor arrangement of  claim 14 , wherein the outer tube includes a cylindrical portion, and wherein the first gas inlet is shaped as one of an outwardly facing scoop structure and an inwardly facing scoop structure on the cylindrical portion. 
     
     
       16. The gas sensor arrangement of  claim 14 , wherein the first gas inlet is shaped as one of an inwardly facing scoop structure and an outwardly facing scoop structure on the conical portion. 
     
     
       17. A gas sensor comprising:
 a sensor housing; 
 a sensing element located within the sensor housing, the sensing element defining a first axis and having a distal end extending from the sensor housing; and 
 a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element, the sensor protection element including:
 an outer tube having a first conical portion, the first conical portion having an inner surface, the outer tube further having a gas inlet, the gas inlet spaced from the first axis, the gas inlet shaped to direct gas into the outer tube to induce a vortex gas flow within the first conical portion of the outer tube, wherein the gas inlet is shaped as one of an outwardly facing scoop structure having an inner concave surface or an inwardly facing scoop structure having an outer concave surface, wherein the gas inlet is configured to direct gas into the first conical portion generally tangentially to the inner surface of the first conical portion, and wherein the outer tube further includes a first gas outlet; and 
 an inner tube disposed within the outer tube, wherein the inner tube has a second conical portion, wherein the inner tube includes a second gas outlet spaced from the first axis, wherein a second axis extends through at least a portion of both the first gas outlet and the second gas outlet, the second axis extending perpendicular to the first axis. 
 
 
     
     
       18. The gas sensor arrangement of  claim 17 , wherein the outer tube includes a cylindrical portion. 
     
     
       19. The gas sensor arrangement of  claim 17 , wherein the sensor protection element further includes a waste outlet located on the first conical portion. 
     
     
       20. The gas sensor of  claim 19 , wherein the first axis extends through the waste outlet.